Line faced marine insulation, and method of production

Abstract

A method of producing a lightweight heat resistant and insulative composite sheet, and containing glass fibers, consisting essentially of homogenized glass fiber and binder materials forming a first layer, binder material extending in a second layer on a surface of the first layer and bonded thereto, woven glass fiber facing cloth extending in a third layer on a surface of the second layer and bonded thereto so that the second layer is sandwiched between the first and third layers, binder material in all layers being cured, to integrate the layers.

I claim:  
     
       1. A method of providing a lightweight heat resistant and insulative composite product sheet, containing glass fibers, the method consisting of the steps: 
       a) providing homogenized glass fiber and binder materials forming a first layer,  
       b) providing binder material extending in a second layer on a surface of the first layer and bonded thereto,  
       c) providing woven glass fiber facing cloth extending in a third layer on a surface of the second layer and bonded thereto so that the second layer is sandwiched between the first and third layers, said third layer cloth having binder content impregnated in the cloth and being less than 10% by weight of the cloth,  
       d) binder material in all layers being cured, to integrate the layers whereby binder impregnated in the cloth is bonded to said second layer binder,  
       e) said third layer cloth having weight between 20 and 60 grams per square foot.  
     
     
       2. The method of  claim 1  wherein the first layer is provided to have a wool-like composition. 
     
     
       3. The method of  claim 1  wherein the first layer is provided to have a density of about ¾ pound per sheet cubic foot, the sheet being about 1.0 inch thick, said product sheet having from 0.375 to 4 inch thickness and from 0.5 to 4.0 pounds per cubic foot density. 
     
     
       4. The method of  claim 1  wherein said second layer binder is provided to have a sprayed on and cured in situ configuration on said surface of the first layer, which is irregular. 
     
     
       5. The method of  claim 1  wherein the bulk of the glass fibers in said first layer is provided to have diameter between 1 and 2 microns. 
     
     
       6. The method of  claim 1  wherein the first layer is provided to consist of about 80% by weight of glass fibers and about 20% by weight of binder, said fibers and binder being homogenized. 
     
     
       7. The method of  claim 1  wherein said first layer is provided to have a wool-like consistency, and a density between 0.5 and 4.0 pounds per cubic foot. 
     
     
       8. The method of  claim 7  wherein said density is about 0.75 pounds per cubic foot. 
     
     
       9. The method which comprises: 
       i) forming a composite sheet as defined in  claim 1 ,  
       ii) and then drying and curing said sheet, at elevated temperature, while being transported.  
     
     
       10. The method of  claim 9  wherein said elevated temperature is between 425° F. and 475° F. 
     
     
       11. The method of  claim 9  wherein said drying and curing at elevated temperature is completed during a time interval between 2 and 4 minutes. 
     
     
       12. The method of  claim 9  including spraying said binder onto an irregular upper surface of said first layer. 
     
     
       13. The method of  claim 12  including progressively feeding said facing cloth onto said sprayed on binder layer just prior to said step ii) of  claim 11 . 
     
     
       14. The method of  claim 1  wherein the composite sheet has density of from 0.5 to 4.0 pounds per cubic foot. 
     
     
       15. The method of  claim 1 , wherein the composite sheet is between 0.25 and 4.0 inches thick. 
     
     
       16. The method of  claim 9  wherein the binder consists of synthetic resin. 
     
     
       17. The method of  claim 16  wherein the resin consists of phenol formaldehyde.